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Manual 36523F
DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGERIndicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNINGIndicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTIONIndicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICEIndicates a hazard that could result in property damage only (including damage to the control). IMPORTANTDesignates an operating tip or maintenance suggestion.
The engine, turbine, or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury, loss of life, or property damage. The overspeed shutdown device must be totally independent of the prime mover control system. An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate.
Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised or updated since this copy was produced. To verify that you have the latest revision, be sure to check the Woodward website: www.woodward.com/pubs/current.pdf The revision level is shown at the bottom of the front cover after the publication number. The latest version of most publications is available at: www.woodward.com/publications If your publication is not there, please contact your customer service representative to get the latest copy.
Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical, or other operating limits may cause personal injury and/or property damage, including damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product certifications or listings.
To prevent damage to a control system that uses an alternator or battery-charging device, make sure the charging device is turned off before disconnecting the battery from the system.
To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules .
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken.
Manual 36523F
Contents
REGULATORY COMPLIANCE ...................................................................... III
Declaration of Conformity ...................................................................................... iii EMC Limitations .................................................................................................... iv
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Contents (cont'd.)
CHAPTER 4. UNIVERSAL PST ................................................................... 21
Introduction .................................................................................................. 21 Features ....................................................................................................... 21 System Requirements ................................................................................. 21 Acquiring Universal PST .............................................................................. 22 Installing Universal PST............................................................................... 23 Wiring the COMM Port to a PC ................................................................... 23 Communications Error ................................................................................. 24 Universal PST User Interface Overview ...................................................... 24 Universal PST Menu Items .......................................................................... 26 Parameter Setup .......................................................................................... 26 Parameter Help ............................................................................................ 27 Synchronizing Universal PST with a DPG ................................................... 27 Status View .................................................................................................. 27 Tuning View ................................................................................................. 28 Chart Recorder ............................................................................................ 28 Engine Speed Data Collection ..................................................................... 29
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Regulatory Compliance
Declaration of Conformity
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EMC Limitations
Cabling All cabling for this unit is limited to less than 30m (98.4). See wiring diagrams for specific cable types required. Power cabling is limited to less than 10m (32.8) in total length from its source; power is intended to be from a local bus structure. The control is not intended to have a power bus that is derived from a plant-wide distribution system, remote source, or similar mains type distribution systems. The power to the control should also be a dedicated circuit, directly to the battery or source via a power and return wire that are routed together. See wiring diagrams for specific cable types required. Power Bus The power bus is intended to be a local bus and to have inductive load kickback events suppressed. Therefore, the controls power input is not designed to withstand a charging system load dump, heavy inductive kickbacks, or heavy surge type pulses. If the control is installed outside its intended usage, as described in this manual, centralized voltage pulse suppression should be implemented to help protect the control and other components on the bus. (See Chapter 6: Installation Instructions.) COMM Port The COMM port is intended to be a service port, with only temporary connection during service or initial configuration. The COMM port is susceptible to some EMC phenomena and possible unintentional battery return currents. 1. Battery return (B-) is also the communication signal common; typically PCs connect the communication signals common to protective earth. The PC grounding can provide an unintended return path for B- currents. If B- and the PC are grounded to protective earth, a communication isolator should be used between the PC and the control. Damage to the PC or control, and/or unintended operation may result from a broken battery return wire or the parallel path. 2. The pins inside the COMM port plug are susceptible to damage by ESD discharges, static electricity arcs. Care should be taken not to touch them with tools or put fingers into the port. Always touch your hand or tool to a grounded piece of metal (discharge ESD) prior to coming in contact with the communication port. 3. The input is susceptible to RF noise such as switching transients and transmitter signals coupled into the communication cable. Cable orientation and short cable length may be used to eliminate these issues, depending on the severity of the environment.
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2.
3.
4.
To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.
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Actuator Compatibility: DYNA 2000 DYNA 2500 DYNA 7000 DYNA 8000 DYNA 70025 DYNA 8200 DYNA 10141 DYNA 8400 Power Flow Series Gas Valves APECS Linkage Free Integral Type Other Models Available: DPG-2100 Series for Genset Applications DPG-2300 Series for Off-Road Vehicles DPG-2400 Series for EFC Valve Applications Woodward 1 APECS 0150 APECS 0250 APECS 0300
Manual 36523F
Electrical
Operating Voltage Range: Rated Output Current: Maximum Surge Current: Connections: Input Signal from the Magnetic Pickup: 930 Vdc * 7 A Maximum (continuous) 14 A (not to exceed ten seconds) Terminal strip with 13 terminals 2.0 VAC RMS minimum during cranking
(*) All cabling for this unit is limited to less than 30m (98.4). Power cabling is limited to less than 10m (32.8) in total length. See wiring diagrams for specific cable types required.
Mechanical
Ambient Operating Temperature: Sealing: Weight: Connections: Mechanical Vibration: -40F to +185F (-40C to +85C) Oil, water, and dust resistant via conformal coating and die cast enclosure 12 oz. (341 g) 13-terminal Euro-style connector Suitable for mounting per SAE J1455; 1 to 500 Hz, 5G amplitude
Performance
Temperature Stability Steady State Speed Band: Engine Speed Measurement Range: Governing Speed Range: ILS Input Voltage Measurement Range: ILS Input Speed Adjust Range: Droop Adjustment Range: Droop Setting Resolution: 0.007 Hz @ 158F (70C) 0.25% over ambient operating temperature range 10 MPU Hertz to 14,000 MPU Hertz 500 MPU Hertz to 11,000 MPU Hertz 2.3752.625 Vdc 3% around the set speed 0 to 10 percent of the set speed Tenths of a percent
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Operating Modes
The user interface operates in two modes: PARAMETER SELECT MODE and PARAMETER EDIT MODE. For each of these modes, the keypad and the display have a unique way of operating. The following tables provide a quick reference to the behavior of the display and the function of each key when a particular operating mode is active. PARAMETER SELECT MODE is the mode used to select a parameter for viewing and editing. This mode is active when the 2-digit value being displayed is blinking. The value displayed is a parameters identification (ID) number. The controllers label lists each user-adjustable parameter and its corresponding ID number.
PARAMETER SELECT MODE LED Display INC key DEC key SELECT key ENTER INC & DEC Simultaneously The ID number of a parameter listed on the controllers label is blinking on and off Increase the parameter ID number by one Decrease the parameter ID number by one Activate PARAMETER EDIT MODE on the parameter whose number was blinking Display the version number of the controllers programming Turn on all LED segments as a test
PARAMETER EDIT MODE is the mode that displays the selected parameters value and allows the value to be modified. This mode is active when the 2-digit value displayed is on and no longer blinking. The value displayed is the selected parameters current value. The displays decimal points have several different meanings while in PARAMETER EDIT MODE. These are described below. Decimal point blinking The selected parameters value can be modified. Decimal point not blinking The selected parameters value cannot be modified; parameter editing is locked and values can only be viewed. This is the case when password protection is active and the unlock code has not been entered. Read about 3
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DPG-2201-00X Digital Controllers the Password parameter in the Parameter Reference chapter for more information about using password protection.
Right digits decimal point is blinking or ON The lower two digits (the tens digit and the ones digit) of a parameters 4-digit value are being displayed. Left digits decimal point is ON The upper two digits (the thousands digit and the hundreds digit) of a parameters 4-digit value are being displayed. The upper two digits of a parameter are always view only and can never be modified directly. The upper two digits change when the lower digits overflow (transition from 99 to 00) or underflow (transition from 00 to 99).
PARAMETER EDIT MODE The value of the selected parameter is displayed. A blinking decimal point means the value can be modified; otherwise, the value is view only. Increase the selected parameters value. Decrease the selected parameters value. Return to PARAMETER SELECT MODE and ignore changes made to the parameters value Save the parameters new value, and return to PARAMETER SELECT MODE Use to display the upper digits of values larger than 99
LED Display
Keypad
The keypad consists of four pushbuttons named ENTER, SELECT, INC, and DEC. ENTER Key The ENTER key is used to exit PARAMETER EDIT MODE and return to PARAMETER SELECT MODE while saving the parameters new va lue to nonvolatile memory. Nonvolatile memory is where parameter values are stored so that they are remembered even when the controller is not being powered. In PARAMETER SELECT MODE, pressing the ENTER key displays the version number of the controllers programming. SELECT Key The SELECT key is used to enter PARAMETER EDIT MODE from PARAMETER SELECT MODE once a particular parameter has been selected for editing. The SELECT key is also used to escape from PARAMETER EDIT MODE and return to PARAMETER SELECT MODE without saving a change in a parameters value. The value a parameter had when PARAMETER EDIT MODE was entered is restored. INC (increase) Key The INC key is used to increase the displayed value.
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In PARAMETER SELECT MODE, each press of the INC key will cause the next higher parameter identification number to be displayed. When the maximum parameter identification number is reached, the next INC key press will cause the first parameter ID number to be displayed. For example: If the controllers label lists 34 parameters, then pressing the INC key when the display is blinking the value 34 will cause the display to wrap around to the first parameter listed and begin blinking the value 01. In PARAMETER EDIT MODE, each INC key press will increase a parameters current value. If the INC key is held down while in PARAMETER EDIT MODE the value will automatically continue to be increased at gradually faster and faster rates until the INC key is released or the parameters maximum allowed value is reached . When the lower two digits display a 99, pressing the INC (increase key) will cause the lower two digits to display a 00 and the hundreds digit will have been increased by 1.
DEC (decrease) Key The DEC (decrease) key is used to decrease the displayed value. In PARAMETER SELECT MODE, each press of the DEC key will cause the next lower parameter number to be displayed. When the first parameter identification number is reached, the next DEC key press will cause the last parameter ID number to be displayed. For example: If the controllers label lists 34 parameters, then pressing the DEC key when the display is blinking the value 01 will cause the display to wrap around to the last parameter listed, which in this case is 34, and blink this new value. In PARAMETER EDIT MODE, each DEC key press will decrease a parameters current value. If the DEC key is held down while in PARAMETER EDIT MODE the value will automatically continue to be decreased at gradually faster and faster rates until the DEC key is released or the parameters minimum allowed value is reached. When the lower two digits display a 00, pressing the DEC (decrease key) will cause the lower two digits to display a 99 and the hundreds digit will have been decreased by 1. INC and DEC Keys Together In PARAMETER EDIT MODE, the INC and DEC keys are used together to view the value of the upper two digits of a 4-digit number. Press and hold both INC and DEC simultaneously to view the value of a 4-digit numbers upper two digits. Note that the left digits decimal point is turned on to indicate that the thousands and the hundreds digits are being displayed. Release INC and DEC and now the tens and the ones digits are again being displayed. Note that the right digits decimal point is blinking if editing is allowed or just ON if editing is not allowed. Note: Not all parameters are 4-digit numbers, in which case the upper digits will always display 0.0 (zero dot zero). In PARAMETER SELECT MODE, pressing both the INC and DEC keys at the same time will cause all LED segments to be turned on. This serves as an LED test. Release the keys to resume displaying the parameter ID number.
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LED Display
The two 7-segment LEDs along with each digits corresponding decimal point are used to display values and indicate the operating mode of the user interface. When the value being displayed by the two 7-segment LEDs is blinking, PARAMETER SELECT MODE is active. When the value displayed is not blinking, the selected parameters value is being displayed and the user interface is in PARAMETER EDIT MODE. The decimal points further indicate which half of a 4-digit value is being displayed and whether editing is allowed. The right digits decimal point is used to indicate that the lower 2 digits of a value (the tens and the ones digits) are being displayed. When the right decimal point is blinking, it means that the value can be modified using the INC key or the DEC key. No blinking means that editing is not allowed or is password protected. The left digits decimal point is used to indicate that the upper 2 digits of a value (the thousands and the hundreds digits) are being displayed. The upper 2 digits are always view only so the right decimal point does not blink. Changes to the upper digits occur when a parameters lower digits overflow or underflow during editing. An overflow occurs when the value 99 is displayed and the INC key is pressed (assuming this is not the parameters maximum value). This will cause the displayed value to become 00 while the non-displayed value in the parameters upper 2 digits will be increased by one. You can verify this by pressing both INC and DEC at the same time to view the new value in the upper digits. For example: If the full 4-digit value of the parameter you are editing is currently 1099, then after pressing the INC key the parameters new value will be 1100. An underflow occurs when the value 00 is displayed and the DEC key is pressed (assuming this is not the parameters minimum value). This will cause the displayed value to become 99 while the non-displayed value in the parameters upper 2 digits will be decreased by one. You can verify this by pressing both INC and DEC at the same time to view the new value in the upper digits. For example: If the full 4-digit value of the parameter you are editing is currently 1800, then after pressing the DEC key the parameters new value will be 1799. When values exceeding 9,999 are to be displayed, the controller uses the hexadecimal numbering system to represent the value of the thousands position. Example 1: The desired set speed is 10,069 Hertz. The upper two digits displayed by the controller will be [A.0], and the lower 2 digits displayed will be [69.].
Decimal to Hexadecimal Conversion Chart Decimal Hexadecimal Value Equivalent 10 A 11 B 12 C 13 D 14 E 15 F
Example 2: The desired set speed is 10,972 Hertz. The upper two digits displayed by the controller will be [A.9] and the lower 2 digits displayed will be [72.].
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Parameters 2, 5, 6, 7, 8, 11, 12, and 33 require adjustment, while adjustments to the other parameters are optional.
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When the No. of Flywheel Teeth parameter is used, the SET SPEED A, SET SPEED B, and IDLE SPEED parameters are displayed as RPM values instead of Hertz values.
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50%
Proportional response
Error (%)
100%
50%
0%
Time
Error Time
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100%
50%
0%
Time
(+)
Error
0 (-)
Time
The error is sampled at regular intervals When the "Rate of change" changes (red dot) the Derivative's impact on controller output changes.
Manual 36523F
terms to be halved to 45, 40, and 25 respectively. These new settings are equivalent to the previous settings with respect to the controllers tuning response and now allow the PID terms to be adjusted higher if needed.
There is measurable acceleration and deceleration that occurs between cylinder firings. As a general rule, less filtering is required the more engine cylinders there are. This is because the number of acceleration-deceleration cycles increases and these oscillations will have lower amplitude. With more cylinders, there is less time for the speed to slow down before the next cylinder firing. Rotational mass also affects the amount of speed signal filtering needed. The more rotational mass, the less filtering is needed. The less rotational mass, the more filtering is needed. Typically, the value 24 works well on small 3- or 4-cylinder engines. A value of 16 is recommended for 6- or 8-cylinder engines. The following formula can also be used to derive a good starting point for the speed filter value for a given engine application. Round the result to the nearest integer. The maximum value allowed is 24. [(No._of_flywheel_teeth) / (No._of_engine_cylinders)] * 0.75 = speed_filter_value
Manual 36523F
Accel Rate to increase the engine speed from Set Speed A to Set Speed B in 2 seconds. [(Set Speed B) (Set Speed A)] / (N seconds) = accel_rate_value in Hertz per second [3960 3300] / 2 = 330 Hertz per second
Manual 36523F
DPG-2201-00X Digital Controllers Exception 2: In cases where the target speed is less the STARTUP SPEED, the startup ramp sequence ends when the target speed is reached. When the No. of Flywheel Teeth parameter is used, the ACCEL RATE, DECEL RATE, and STARTUP RATE parameters are displayed as a RPM quantity per second instead of Hz/sec values. The given rate formulas can be used to compute rates in terms of RPM values by substituting the Hertz speed values with RPM speed values.
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parameter is set to any value from 1 to 100, which corresponds to 0.1% to 10.0% droop. The following formula determines the no load droop speed. [(selected_set_speed) / ((1000 value_of_%_DROOP) / 1000)] = no_load_droop_speed For example: If 5% droop is desired, set the percent droop value to 50. Now if the selected set speed is 1800 RPM then the no load droop speed will be: [(1800 RPM) / ((1000 50) / 1000)] = 1800 RPM / 0.95 = 1895 RPM NOTE: This parameter can only be modified during the Droop Calibration Procedure. See the Calibration Instructions chapter for more information. Droop mode relies on knowing the actuator position. The actuators position corresponds to the amount of fuel being delivered to the engine. The DPG-2201-00X controller senses electrical current flow through the actuator to determine its position. This method of position sensing does not work with all actuators.
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The controller must be turned off to clear the over speed detection before the engine can be restarted.
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Features
Universal PST features include: Automatic configuration to each DPG when communications are established Read/write access to all DPG programmable parameters and features View each parameter's default, minimum, and maximum values Diagnostics utilizing automatic refresh of DPG status Save and open DPG setup data information to and from a file for reuse Single button read to get the current values of all parameters Single button write to program a DPG with previously saved setup values Engine speed monitoring via a chart recorder to aid in tuning the controller Saving chart recorder data to a Microsoft Excel compatible file Help information on each of the controllers parameters Help information on using the Universal PST
System Requirements
Universal PST minimum system requirements: Pentium 133 MHz PC 50 MB of hard disk space 64 MB of RAM Display resolution set to SVGA (800x600) or higher Windows 98se, NT 4.0, 2000, and XP or greater Windows 95 or ME not supported
CAUTION
An unsafe condition could occur with improper use of these software tools. Only trained personnel should have access to these tools. Woodward 21
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This will automatically redirect you to the Universal PST download page where you can click on the word Download to begin the download process. Once you are logged into the Woodward download site you are presented with the File Download dialog box shown below, or one similar. Click the [Save] button and choose a folder to save the download to.
NOTE: Due to the large file size, it is recommended that the [Open] button not be used because this would try to run the self-extracting executable from the web site.
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DPG-22XX SIGNAL No connection Transmit data to PC Receive data from PC COMMON +5 Vdc (Do NOT connect at the PC end) No connection
CONNECTS TO: N/C PC receive (RxD) DB9 pin 2 PC transmit (TxD) DB9 pin 3 PC common DB9 pin 5 N/C
RJ11M 654321
N/C
DB9F
Remote access via the COMM port is intended for connection only while programming, tuning, and troubleshooting the control/ engine. It is a service port and not intended for permanent connection of a PC and/or cable. Woodward 23
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Communications Error
The following message window appears when Universal PST is running and unable to communicate with a DPG.
After the problem is found and corrected, you can either restart Universal PST or press the <Read All> button to clear the error message. The <Read All> button is near the lower left corner of Universal PSTs main startup screen.
In Table View the user can: View the current values for all user programmable parameters in the Parameter Setup panel. Edit a parameters value by double-clicking on a cell in the Value column of the table. Press the <Read All> button to refresh the values displayed in the Parameter Setup panel. Press the <Write All> button to transmit setup values to the controller. Press the <View Status> button to display read only parameters in the Status View panel.
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DPG-2201-00X Digital Controllers Press the <View Chart> button to set the display mode to Chart View. Select items from the menu.
CHART VIEW
In Chart View the user can: Monitor engine speed in real-time. Adjust the horizontal and vertical scale settings of the chart recorder. Edit parameter values related to controller tuning. These same parameters are also on the main parameter setup table. Press the <Data File => button to open a file for saving chart recorder data. Press the <Data Reset> button to start data collection to the open file at the beginning. Press the <Pause Chart> button to stop the chart recorder, which also stops writing data to the file. Press the <Continue> button to turn the chart recorder back on. Press the <View Table> button to set the display mode back to Table View. Select items from the menu.
NOTE: Pressing a button means positioning the mouse pointer over the button and clicking the left mouse button.
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Use the View menu to: Select Parameter Table view (Table View) Select Chart Recorder view (Chart View)
Use the Port menu to: Select the PCs serial port that is connected to the DPG-2000
Use the Help menu to access: Help on the Universal PST for DPG Help on the DPG-2000 product that is currently in communication with the PC Information about the Universal PST for DPG application
Parameter Setup
The Parameter Setup panel displays a table where each row shows the Name of a user programmable parameter, its current Value, and the parameters Default, Minimum, and Maximum values. To modify a parameters current value, it must first be selected. Do this by double clicking the left mouse button on a cell in the table that is at the intersection of the parameters row and the Value column. The selected cell will be highlighted and the value can now be modified. When done modifying the value, press the computer keyboards <Enter> key to transmit the new value to the controller.
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In the figure shown below, the Set Speed A value has been selected for editing.
Parameter Help
To get help on a particular parameter, single click the left mouse button on a parameters Value, then press <Ctrl><F1> on the computers keyboard. <Ctrl><F1> means press and hold the <Ctrl> key while the <F1> key is pressed and released. This opens the DPG online help file and automatically jumps to the selected parameters help page. NOTE: Complete online help for each DPG controller is also accessible by selecting either Governor Help Contents or Parameter Definitions from the Universal PST Help menu.
Status View
The Status View panel is displayed only after pressing the <View Status> button. The Status View panel is part of the Table View display mode. The Status View panel displays a table where each row shows the Name of a read only parameter and its current Value (when Auto Read is ON) Press (left mouse click) the <START Monitoring> button to have the Universal PST program automatically refresh the Values. Press the <STOP Monitoring> button to disable automatic refresh.
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Tuning View
The Tuning View panel is displayed only after pressing the <View Chart> button. The Tuning View panel is part of the Chart View display mode. To modify a tuning parameters current value, it must first be selected. Do this by double-clicking the left mouse button on a cell in the table that is at the intersection of the parameters row and the Value column. The selected cell will be highlighted and the value can now be modified. When done modifying the value, press the computer keyboards <Enter> key to transmit the new value to the controller.
Chart Recorder
The chart recorder is part of the Chart View display mode. Each time Chart View is entered the last used Data File is reset, the Vertical Scale defaults to [0 Hz to 12000 Hz], and the Horizontal scale defaults to 20 seconds. The chart recorders display characteristics are configured using the Vertical Scale options, the Horizontal Scale options, and the Chart Recorder Signal Filtering options.
The Vertical Scale options provide three different ways to view engine speed data. The [0 to 12000 Hz] option is the default and sets the vertical axis range to its absolute minimum and maximum measurable values. The [_____] to [______] Hz option allows you to enter the minimum and maximum speed values to zoom in on a viewing range of interest. The +/- 10% of [______] Hz option is primarily used to zoom in on the target speed and center it in the chart recorder. This is most useful during controller tuning to see if the engine speed stays within +/- 10% of the target speed during load on/off cycling. The Horizontal Scale options allow you to set how much data is displayed in the chart recorder window. Larger values compress the display and show more data. Smaller numbers expand the display and show less data. A Horizontal Scale setting of 20 seconds is approximately the same as a 5-millimeter per second paper travel speed of a conventional paper tape chart recorder. The Chart Recorder Signal Filtering options can be used to smooth out noisy signals. The default setting is Min, which is no filtering. Note that filtering will round out peaks and give a less accurate display of the speeds actually measured by the DPG.
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The <Data File => button opens a dialog box allowing you to set the base file name where chart recorder data will be saved. A two-digit suffix is automatically appended to the file name that is given and serves the following purpose. Each engine speed data file is considered full after recording 60,000 data points which is approximately 10-12 minutes of data. The two-digit suffix is used to automatically continue collecting data to new files with the same base file name but with increasing numeric suffixes. The first 60,000 data points are saved in filename00.csv and the next 60,000 data point are saved in filename01.csv, and so on until a million data points are collected. This is to prevent each speed data file from exceeding the 65,536 row limit of Microsoft Excel. The <Data Reset> button is used to clear out the data collection buffer and overwrite the zero suffixed data collection file. Data collection starts from the beginning of filename00.txt where filename is the base file name previously used. The progress bar shown to the right of the <Data Reset> button indicates how full the complete set of data files is. A total of one million data points (approximately 3.5 hours of data) can be collected before the progress bar displays the message The Data File is FULL. In order to start recording data again without overwrit ing previously collected data, use the <Data File => button to create a new base file name in which to receive additional engine speed information. The <Pause Chart> button stops chart recorder and Data File updates. After pressing this button the <Continue> button is displayed. Press the <Continue> button to turn the chart recorder back on and continue recording engine speed data to the current target file. Use the <View Table> button to return to the Table View display mode. Be sure to open a new Data File before returning to Table View if the data already collected needs to be saved. The active data file is automatically reset each time the Chart View display mode becomes active.
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NOTE 1: Modify Gain Factor only if you run out of adjustment in a PID or OVG term. NOTE 2: For the Speed Filter, typically the value 24 works well on small 3- or 4-cylinder engines. A value of 16 is recommended for 6- or 8-cylinder engines.
Tuning Methodology
Once the engine is running, the following procedure may be used to discover more optimum values for PID and the overall gain parameters (OVG). The goal would be to find PID values that allow the controller to govern the engine well at a variety of different speeds and loads while only requiring gain adjustment at those different speeds. Follow these steps: 1. Set the integral and derivative terms to 0. 2. 3. 4. 5. 6. 7. Set the overall gain low (<20). Increase the proportional term until you get continuous oscillations greater than 2 Hz. Reduce the proportional term by 25% to 50%. Now experiment with small value changes in the derivative to dampen out ringing in response to load transients. Add some integral to eliminate any steady-state error in the engines speed and help decrease error recovery time. The overall gain can be increased to improve response time while keeping the ratios of the PID terms relative to each other constant. 30
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During each of the steps 3 through 6, you need to disturb the system by adding and removing a load from the engine to check the controllers response to the load transition. START WITH SMALL LOADS. Note that without integral, a speed error may persist after a load-on load-off transition. Therefore, during steps 3-5 you should temporarily increase the integral to get the engine speed back to the set speed, and then reset the integral to a lower value again while working to find good proportional and derivative values. Repeat steps 3-7 as needed to find a Proportional value, Integral value, and a Derivative value that work well with a variety of overall gain values and different load transients.
The Derivative works on the Instantaneous Rate of Change in the amount of error +E
Error
Time
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Startup Sequence
The following example describes the DPG-22201-00X startup sequence. Startup Sequence Example
A 3500 3000
IDLE HOLD TIME = 100 SET SPEED A = 3500 Hz
Speed in Hert z
2500
IDLE SPEED = 1500 Hz
2000
ACCEL RATE = 500 Hz/sec
1500
STARTUP RATE = 250 Hz/sec
1000 500 0 0 5 10 15 20 25 30 35 40
STARTUP SPEED = 500 Hz
Time in seconds
Engine cranking begins at point A. After a short time, the engine starts and at point B the engine speed exceeds the STARTUP SPEED (the initial target speed) and the controller now considers the engine to be running. The controllers startup sequence begins at point B by ramping the target speed up from the STARTUP SPEED at the STARTUP RATE. In this example, the STARTUP SPEED is set to 500 Hertz, the STARTUP RATE is set equal to 250 Hertz per second, and the IDLE SPEED is set to 1500 Hertz. It will take 4 seconds for the target speed to ramp up 1000 Hertz (IDLE SPEED minus STARTUP SPEED) and reach point C. This example uses the IDLE HOLD TIME and has it set to 100 tenths of a second so the target speed will be held at the IDLE SPEED (1500 Hertz in this example) for 10 seconds. At point D, the IDLE HOLD TIME has elapsed and the target speed is ramped up at the ACCEL RATE. In this example, the ACCEL RATE is set equal to 500 Hertz per second. The example also has SET SPEED A set at 3500 Hertz so it will take 4 seconds for the target speed to ramp up 2000 Hertz from the IDLE SPEED. Ramping stops at point E when the target speed reaches SET SPEED A. The startup sequence also ends at point E assuming the engine speed has been tracking the target speed and has reached SET SPEED A.
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Calibration Sequence
Step 1 Step 2 Make sure the engine is running at the selected set speed and the controller is tuned. User Interface/ Universal PST: Enter a value of 41 into the Password parameter to allow editing of the droop related parameters. User Interface: Select the "% DROOP" parameter and adjust its value while the engine is running with no load applied. Step 3 Universal PST: While the engine is running with no load applied, enter a value for the desired percentage of droop in to the "Percent Droop" parameter and press ENTER. Engine speed will increase to: [(selected_set_speed) / ((1000 - value_of_%_DROOP) / 1000)]. User Interface: Allow the engine to stabilize at the no load droop speed then press the controller's ENTER key to set the percent droop. Universal PST: Allow the engine to stabilize at the no load droop speed. From the Universal PST Status View window, enter the value displayed for the " Actuator %FS" in to the "No Load Cal" parameter and press ENTER. The engine speed will return to the selected set speed. No Load Calibration is now complete. User Interface: Select the "FULL LOAD CAL" parameter. Engine speed will return to the selected set speed. Universal PST: Proceed to Step 6. Step 6 Now apply full load to the engine and allow the speed to stabilize. (Assumes the controller was previously tuned.) User Interface: Wait 5 seconds, then press the controller's ENTER key to record the calibration value. Step 7 Universal PST: Wait 5 seconds, then from the Universal PST Status View window, enter the value displayed for the " Actuator %FS" in to the "Full Load Cal" parameter and press ENTER. Full load calibration is now complete. Step 8 Remove the load from the engine. The engine speed will increase to the no load droop speed. Droop calibration is complete.
Step 4
Step 5
After droop calibration, the difference between the No Load Cal and Full Load Cal parameter value should be greater than 100 for best operation of droop. The droop function may still work for smaller differences but with less accuracy. You may be able to get some improvement by modifying or adjusting actuator linkage or adding springs. The goal is to achieve a wider range of measured current change through the actuator from no load to full load. If the calibrated range is too small droop may not work at all. The actuator position sensing method used by this controller does not work with all actuators. A different actuator may be required or a different system solution altogether may be needed by your application, such as an actuator with a position feedback potentiometer and a supporting controller. Woodward 34
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1 2 3 4 5 6 7 8 9 10 11 12 13
BAT+ BATACT ACT MPU+ MPUSHIELD SPEED SEL ILS SIGNAL ILS REF (2.5 V) DEC SPEED INC SPEED +5 Vdc OUT
Battery positive (930 Vdc) * Battery negative * Actuator drive output Actuator drive return Magnetic pickup signal input Magnetic pickup ground Ground connection for cable shielding Digital input used to select the target set speed ILS input used to adjust speed +/- 3% Supply voltage around which ILS operates Digital input used to decrease the selected set speed remotely Digital input used to increase the selected set speed remotely Supply voltage for the digital inputs
(*) DC power bus cable must be less than 10 meters (32.80 feet). All other cables must be less than 30 meters (98.43 feet).
Recommended Mounting
The controller is designed to be panel mounted and its chassis electrically bonded to the same protective reference as the engine structure. The mounting should protect the controller from exposure to rain, weather, and direct sunlight. The controller should not be mounted on the engine or in an environment that exceeds the mechanical specifications outlined in Chapter 1 of this manual. The controller should be mounted in a position to allow access to the user interface, the COMM port, and the terminal strip.
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Wiring Diagram
All cabling for DPG 2201-00X controllers is limited to less than 30m (98.4). Power cabling is limited to less than 10m (32.8) in total length. The wiring diagrams below show specific cable types required.
CAUTION
To prevent damage to the controller, make sure that it is wired in accordance with the wiring instructions and diagrams in this manual. Do not tin the leads before placing them into the terminals. Ensure the terminals are tightened properly to secure wires.
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Centralized Suppression
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EFC Actuator
DPG control
Optional
Optional
Optional
Switched source
24V buss may use two 15KP17CA parts (WGC p/n 1682-1059).
Battery
Discrete parts are available from Woodward as: 12V: 8923-1271.KIT 24V: 8923-1272.KIT
V47ZA7 MOV to chassis at the control (24V& 12V system, WGC p/n 1688-411)
NOTES: 1. Power and return cables to the control are routed together to minimize the noise pickup and emissions. Similarly, the power and return to the actuator must also be routed together, but may be separated from the controls power leads. 2. MOV and TVS suppression devices are recommended based on the typical pulse levels that might be seen in Group 1 or Group 2 engine applications and the internal circuitry of the control. 3. Other suppression devices may be used, but clamping voltages and energy handling capability are important, as operating voltage and energy handling capability requirements are dependant on the full system implementation. Examples: (a) Two 15KP17CA and V47ZA7 through-hole parts are available from Woodward as 8923-1272.KIT. This kit is for a 24V system. It will suppress alternator load dump from alternators within the 200A range, as well as indirect lightning pulses that may be coupled to the power bus. Parallel inductive loads still need to be suppressed because pulses from unsuppressed parallel loads may be clamped at voltages too high to protect the control. Two 15KP13CA and one V47ZA7 through-hole parts are available from Woodward as 8923-1271.KIT. This kit is for a 12V system with an alternator within the 100A range, unsuppressed switched inductive loads in parallel with the control, and indirect lightning pulses that may be coupled to the power bus.
(b)
4. Suppression kits available from Woodward are intended to suppress the majority of the likely pulses. However, they will not protect against all system level implementations outside the intended usage of the control. A system level evaluation of what pulses may be present should be undertaken.
Woodward
12V buss may use two 15KP13CA parts. (WGC p/n 1682-1061).
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Troubleshooting Table
SYMPTOM LED Display Does Not Light Up When Controller Is Powered REMEDY BAT + and BAT leads are reversed. Check wiring. Battery voltage too low. Should measure between 9 and 30 VDC Controller is defective. Replace it. The parameters value is the maximum value allowed. The parameters value is the minimum value allowed. A display code is active. Refer to the Display Codes section above Password protection is enabled. Enter Password Keypad failure, replace unit. Actuator leads not connected or shorted. No fuel source. Turn on fuel source. Battery voltage is low. Charge or replace the battery. Set speed is lower than crank speed. Increase the set speed. Startup Rate setting is too low. The target speed ramps up too slow. Startup Limit is too low, limiting the actuator drive signal too much. Is the MPU speed signal present? It should read 2.0 VRMS minimum. Adjust magnetic pickup (MPU) gap. Try reversing the MPU leads. If a speed signal is present, measure actuator output duty cycle. If not greater than 5%, then restore all parameter values to factory default settings and crank the engine again. Increase the Proportional value. Increase the appropriate OVG (overall gain) value. Use the Startup Limit. Decrease the Startup Ramp Rate. Improve PID tuning. Integral too low or zero Derivative too low or zero PID values are too low. A tuning that is too soft can prevent the controller from delivering the needed actuator drive signal to reach the set speed.
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Improve PID tuning. Torque limit is set too low. Increase the torque limit. Fuel is restricted. Check actuator linkage. Measure the ILS input signal to see if the measurement is between 2.375 VDC and 2.625 VDC. Use shielded wiring. The No Load and Full Load values are not calibrated. Perform the Droop Calibration Procedure.
Difference between No Load and Full Load calibration values is too small. Should be > 100 for best performance. Modify or adjust actuator linkage to increase range of actuator loading. If finer droop control is required, then use a DPG-2223-00X controller.
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Packing a Control Use the following materials when returning a complete control: protective caps on any connectors; antistatic protective bags on all electronic modules; packing materials that will not damage the surface of the unit; at least 100 mm (4 inches) of tightly packed, industry-approved packing material; a packing carton with double walls; a strong tape around the outside of the carton for increased strength.
To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.
Replacement Parts
When ordering replacement parts for controls, include the following information: the part number(s) (XXXX-XXXX) that is on the enclosure nameplate; the unit serial number, which is also on the nameplate.
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Engineering Services
Woodward offers various Engineering Services for our products. For these services, you can contact us by telephone, by email, or through the Woodward website. Technical Support Product Training Field Service Technical Support is available from your equipment system supplier, your local FullService Distributor, or from many of Woodwards worldwide locations, depending upon the product and application. This service can assist you with technical questions or problem solving during the normal business hours of the Woodward location you contact. Emergency assistance is also available during non-business hours by phoning Woodward and stating the urgency of your problem. Product Training is available as standard classes at many of our worldwide locations. We also offer customized classes, which can be tailored to your needs and can be held at one of our locations or at your site. This training, conducted by experienced personnel, will assure that you will be able to maintain system reliability and availability. Field Service engineering on-site support is available, depending on the product and location, from many of our worldwide locations or from one of our Full-Service Distributors. The field engineers are experienced both on Woodward products as well as on much of the non-Woodward equipment with which our products interface. For information on these services, please contact us via telephone, email us, or use our website and reference www.woodward.com/support, and then Customer Support.
Engine Systems
FACILITY PHONE NUMBER
Turbine Systems
FACILITY PHONE NUMBER
Brazil ------------- +55 (19) 3708 4800 China ------------+86 (512) 6762 6727 Germany: Kempen --- +49 (0) 21 52 14 51 Stuttgart ----- +49 (711) 78954-0 India --------------- +91 (129) 4097100 Japan -------------- +81 (43) 213-2191 Korea--------------- +82 (51) 636-7080 Poland -------------- +48 12 618 92 00 United States----- +1 (970) 482-5811
Brazil ------------- +55 (19) 3708 4800 China ------------+86 (512) 6762 6727 Germany: Stuttgart ----- +49 (711) 78954-0 India --------------- +91 (129) 4097100 Japan -------------- +81 (43) 213-2191 Korea--------------- +82 (51) 636-7080 The Netherlands - +31 (23) 5661111 United States----- +1 (970) 482-5811
Brazil ------------- +55 (19) 3708 4800 China ------------+86 (512) 6762 6727
India --------------- +91 (129) 4097100 Japan -------------- +81 (43) 213-2191 Korea--------------- +82 (51) 636-7080 The Netherlands - +31 (23) 5661111 United States----- +1 (970) 482-5811
You can also contact the Woodward Customer Service Department or consult our worldwide directory on Woodwards website (www.woodward.com/support) for the name of your nearest Woodward distributor or service facility. For the most current product support and contact information, please refer to the latest version of publication 51337 at www.woodward.com/publications.
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Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information. Please write it down here before phoning:
General
Your Name Site Location Phone Number Fax Number
Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:
Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or the menu settings written down and with you at the time of the call.
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We appreciate your comments about the content of our publications. Send comments to: icinfo@woodward.com Please reference publication 36523.
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Email and Websitewww.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.
2010/1/Skokie